How the 2PGY1010 Hydraulic Roller Crusher turned excavation waste into premium manufactured sand and solved the disposal headache.
The Problem: Tunnel Muck Disposal & Poor Sand Quality
basalt sand maker
A Hubei Shiyan infrastructure project faced two problems: tunnel excavation produced massive basalt muck requiring costly disposal, while concrete production demanded quality sand. Initial impact crusher trials failed — high-speed impact generated excessive flaky particles exceeding concrete specs, lacked cubical shape and proper gradation, and hammers wore out rapidly under abrasive basalt, driving maintenance costs and downtime. With muck piling up and sand quality falling short, the project needed a solution to turn waste into a valuable resource while meeting strict engineering standards.
The Solution: 2PGY1010 Hydraulic Roller Crusher Integration
The plant replaced its impact crusher with HSM’s 2PGY1010 Full-Hydraulic Roller Crusher, paired with a 1860 two-deck vibrating screen. The basalt muck, crushed to under 10mm, was fed into the roller crusher. Operating at low speed with synchronized hydraulic pressure, the double rolls applied compression and shearing forces to fracture the basalt cleanly along natural cleavage planes.
Unlike impact crushing, which shatters material randomly, the roller crusher’s lamination principle produced cubical particles with minimal fines. The hydraulic system allowed precise gap adjustment, delivering consistent output size control. A self-cleaning tooth design prevented clogging even when the muck contained moisture or clay. The entire system ran continuously with low noise and dust emissions.
Proven Performance Data
| Metrics | Original Impact Setup | 2PGY1010 Roller Circuit | Net Gain |
|---|---|---|---|
| Needle-Flake Content | Exceeded spec limits | Below 8% | Grade-A quality |
| Sand Particle Shape | Irregular, elongated | Cubical, well-graded | Premium concrete sand |
| Discharge Size Control | Unstable | 0–3mm adjustable | Precise gradation |
| Maintenance Frequency | Frequent hammer changes | Minimal wear part replacement | Reduced downtime |
| Material Utilization | Waste disposal cost | Value-added sand product | Waste turned profit |
The Results
After switching to the HSM roller crusher, the project achieved significant improvements:
Waste became a resource. The tunnel muck, once a disposal liability, was transformed into high-quality manufactured sand that met local construction standards. The project eliminated costly muck hauling and landfilling while generating a valuable product.
Sand quality met engineering standards. The cubical particle shape and low needle-flake content made the sand suitable for high-grade concrete and asphalt applications. The uniform gradation (0–3mm) ensured consistent concrete workability and strength.
Production ran continuously. Operators reported stable performance with minimal maintenance interventions. The roller crusher’s robust design handled the abrasive basalt without frequent stoppages.
Basalt sand maker finished product
Environmental and economic benefits aligned. The project reduced its environmental footprint by repurposing excavation waste while securing a reliable local sand supply for infrastructure construction.
Upgrade to High-Quality Basalt Sand Production
Stop paying to dispose of tunnel muck and start turning it into premium sand. Send us your material specifications and target capacity to receive a custom plant layout.
GET CUSTOM BASALT SAND PLANT LAYOUT BLUEPRINT→https://www.hsmcrusher.com/contact-us
